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Table of Contents
Summary of Contents for MCi C Series
- Page 1 OPERATIONS MANUAL MODEL C1 ELECTRIC CHEMICAL INJECTION SYSTEM www.mcisolutions.ca...
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Page 2: Table Of Contents
GENERAL SAFETY Table Of Contents General Safety Symbol Usage Proper Use Sources of Danger Authorized Operators Personal Protective Equipment In Case of Emergency System Specifications Electric Drive Dimensions Mounting Dimensions Static Head Requirements Electrical Specifications General Specifications Output Performance Installation General Standard Package Contents Plumbing Overview... -
Page 3: General Safety
General Safety Symbol Usage Designates an imminent danger In case of non-observance of this infor- DANGER! mation, death or severe injuries are an imminent risk Designates possibility of a dangerous situation In case of non-observ- CAUTION! ance of this information, death or severe injuries can occur Designates areas where the potential for severe crush injury exists These crush injuries can result in serious bodily injury Electrical Shock Hazard Warning indicates a potential injury hazard that... -
Page 4: Proper Use
System has been modified by others without authorization from MCI When replacing parts in the System, use only spare parts approved by MCI (Refer to the Bill of Materials section in this manual for more information ) -
Page 5: Authorized Operators
Authorized Operators Only persons who have been properly authorized and trained by MCI or its authorized agent may work on or with this equipment The owner must: ■ Clearly define and ensure the observance of the responsibilities for all tasks performed in con- nection with the System ■... -
Page 6: Personal Protective Equipment
MCI’s sole election, the repair or replacement of the product... -
Page 7: System Specifications
System Specifications Electric Drive Dimensions 370 mm (14 5 in) 234 mm (9 2 in) LID CLOSED 190 mm 335 mm (7 5 in) (13 2 in) 330 mm (13 0 in) Mounting Dimensions 173 mm (6 8 in) C/L TO C/L 7 9 mm (0 313 in) Diam ( x 4 ) -
Page 8: Static Head Requirements
GENERAL SAFETY Static Head Requirements MINIMUM (CL TO CL) 305 mm (12 0 in) Electrical Specifications Electrical Rating 24V DC Classification CSA CLASS 1 DIVISION 2 Enclosure Rating Nema 3R Temperature Code Motor Type 4 Pole Stepper Motor, 1 8 Degree Step Inrush Current 950 (mA) Avg Power Consumption... -
Page 9: General Specifications
General Specifications N-seal Leak Containment Adaptor Standard Variable Speed Controller Electronic/ MOSFET Electro-mechanical contactors / Relays Electro-mechanical Timers Dip Switch Fluid End Carbon Steel [316L S S Upgrade available] Fluid End Suction and Discharge Seals OMX Fluoroelastomer® Secondary Containment Static Seals Teflon®... -
Page 10: Installation
Congratulations You have chosen the finest, most accurate electrically powered chemical injection Sys- tem available Before Installation, please inspect the pump carefully for any possible in-transit dam- age If the pump appears damaged, call your local distributor or call MCI customer service direct at +1 888 263 4565... -
Page 11: Plumbing Overview
Ensure all process valves are closed prior to disconnecting or re-installing any chemical injection System To avoid over-pressuring chemical discharge lines MCI requires placing a properly tested and calibrated Pressure Relief valve (PRV) between the discharge port of the fluid end and the process injection point... - Page 12 System It is highly recommended to use a pre-suction in-line filter on all Systems MCI offers in-line filter kits for all pump models Please contact customer service for the...
- Page 13 Tube Connector - 3/8” Union Tee - 3/8” Pressure relief valve kits are available direct from MCI Kits include all tubing [where applicable] and fittings required to complete the installation Contact customer service for more information: +1 888 263 4565...
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Page 14: Power Supply
GENERAL SAFETY In-line filter assemblies are available direct from MCI Kits include all tubing [where applicable] and fittings required to complete the installation Contact customer service for more information: +1 888 263 4565 The 1/4” NPT drain port shown [Arrow] is a general... - Page 15 Power Supply Requirement - 24 V DC Power supply cannot exceed 28 V or damage to electrical components will CAUTION! result Power Supply Wiring Do not connect or disconnect motor while the controller is powered or CAUTION! damage to the controller can result To ensure safe and proper System operation DO NOT exceed maximum recommended injection pressures.
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Page 16: System Startup
GENERAL SAFETY System Startup STEP 1 WIRING INTERFACE Wire 24V DC power supply out to the main terminal block on the pumps front access panel, always ensure wiring polarity is correct to prevent system damage CAUTION: System will start automatically Model C1 pumps are equipped with COLDStart technology This technology ensures proper operation during the winter months by temporarily increasing the motors supply current at startup When the sys- tem is in COLD start mode 'UP' will appear on the digital display The System will automatically revert to... -
Page 17: Operating Instructions
CAUTION! operating this equipment MCI’s user interface has been designed to simplify the process of setting and adjusting the chemical injection drive This section has been included to explain how to use the 3 button controller interface Integrated RED LED - (Blinks... -
Page 18: Setting Flow Rate
GENERAL SAFETY Setting Flow Rate STEP 1 Determine Systems plunger size *[1/4”, 3/8”, 1/2” or 11/16” Diameter] Mci s lunger lAbels Are included with ysteMs to help quickly identify plunger size he decAl cAn be found on the front top right hAnd corner of your electric drive enclosure... - Page 19 PLUNGER SIZE (DIAMETER) STROKES 1/4" 3/8" 1/2" 11/16" LITRES PER DAY (OUTPUT) MINUTE (CON STEP 4 0.12 0.26 0.46 0.86 Select desired output volume from appropriate 'Litres Per Day' column for your specified plunger size 0.23 0.44 0.79 1.49 Determine the 'Strokes Per Minute' setting for your chosen output volume by looking to the far left of the selected volume row [ 0.35 0.66...
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Page 20: Troubleshooting
If any valves are found to be closed and if safe to do so, open valves with the drive Original controller replaced MCI offers many drive options that require specific controllers Before installing a new pump controller please contact MCI customer service: +1 250 888 4565 to confirm compatibility Please provide the Systems... - Page 21 Check Valve bodies do not need replacement when failing to seat Rebuild seal kits are available from MCI or your authorized pump dis- tributor Please contact MCI customer service for more information:...
- Page 22 LEAK AREA MCI chemical injection Systems are designed to be simple to operate and easy to repair The best way to ensure reliable and efficient service is to have your pump repaired at the factory If non-factory repairs are to be carried out please read and understand all maintenance procedures found under the 'Mainten-...
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Page 23: Bill Of Materials
Bill of Materials Material Codes The following pages include multiple System views with part numbers and material codes to assist in identifying parts in the System’s assembly If additional information is required please contact customer service: +1 250 888 4565 When con- tacting customer service it is helpful if you have the System serial number available to ensure proper replacement parts are recommended [Serial Numbers can be found on the front cover of the Systems enclosure]... -
Page 24: General System Detail View
GENERAL SAFETY General System Detail View Fluid End Plunger Size Component 1/4" 3/8" 1/2" 11/16" izes FUSE HOLDER BODY AND CAP FUSE [2 5A] OFFSET DISTANCE PIECE O-RING - TEFLON (-031) fMt fluid end FMT-C1- FMT-C1- FMT-C1- FMT-C1- cArbon steel AsseMbly CS-04 CS-06... -
Page 25: Fmt Fluid End
FMT Fluid End Fluid End Plunger Size Component 1/4" 3/8" 1/2" 11/16" izes SEAL RETAINER SCREWS #10-32 SEAL RETAINER CAP SCREW - 1/4” cArbon steel ROD END stAinless steel TEFLON® LOW PRESSURE O-RING [-029] SPRING ENERGIZED SEAL TEFLON® HIGH PRESSURE O-RING DISCHARGE CHECK VALVE BUSHING DISCHARGE BALL CHECK SPRING STAINLESS STEEL BALL - 0 375 DIAM... -
Page 26: Plunger Seals
GENERAL SAFETY Fluid End Plunger Size Component 1/4" 3/8" 1/2" 11/16" izes STAINLESS STEEL BALL - 0 250 DISCHARGE CHECK VALVE SEAT PRIMING SCREW PIPE PLUG - 1/8” NPT CARBON STEEL BLIND END STAINLESS STEEL SUCTION CHECK VALVE SEAT TUNGSTEN CARBIDE PLUNGER Plunger Seals Fluid End Plunger Size Component... -
Page 27: In-Line Filter
In-line Filter Fluid End Plunger Size Component 1/4" 3/8" 1/2" 11/16" odels TUBE CONNECTOR - 3/8” IN-LINE STRAINER - 440 MICRON (3/8” TUBE) REPLACEMENT FILTER ELEMENT Pressure Relief Valve www.mcisolutions.ca... - Page 28 GENERAL SAFETY Fluid End Plunger Size Component 1/4" 3/8" 1/2" 11/16" odels MALE CONNECTOR - 1/4” NPT X 3/8” TUBE PRESSURE RELIEF VALVE RUN TEE - 1/4” NPT TUBE CONNECTOR - 3/8” UNION TEE - 3/8” STAINLESS STEEL TUBING - 3/8” To ensure accurate and prompt parts delivery, the following information must be provided when ordering components: Serial Number - Located on the front cover of the Systems enclosure...
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Page 29: Maintenance
Maintenance Preventative Maintenance Schedule MCI series Systems are designed to provide trouble free service for many years with little inspection, lubrication or other routine maintenance However, like any other mechanical device proper mainten- ance can extend the life cycle of the System... -
Page 30: Lubrication Details
GENERAL SAFETY Lubrication Details REMOVE PUMP TO ACCESS GREASE FITTING WHERE SHOWN [ARROW] Grease Fitting Type: 1/4 inch Straight Always disconnect power to the System before lubricating ballscrew assembly To be used with Lincoln® pistol grip 18 in grease gun [ ] It is recommended to add 2 grams or equivAlent of grease on an annual basis [This is equivalent to approximately 2 5 strokes on typical pistol/hand grip... - Page 31 STEP 4 (1) Replacement seal kit required - See ‘Page 24’ for details STEP 1 Tilt and pull plunger [A] to remove* (As shown) Inspect for any damages and clean thoroughly Disconnect Systems power supply Close all suction and dis- *The System must be located in the extended position (All the charge isolation valves and remove both the suction and dis- way to the right) to allow plunger removal [See Step 1]...
- Page 32 GENERAL SAFETY STEP 6 STEP 8 Remove high pressure dynamic seal [A] and static Teflon® face Slide seal retainer [A] onto plunger [B] ( ) followed inches seal [B] from rod end and discard by a NEW low pressure seal [C] as shown USE CAUTION NOT TO SCRATCH SEAL FACES WHEN RE- SPRING MOVING SEALS...
- Page 33 STEP 10 PRESS SEAL AND SEAL RETAINER INTO POSITION SLOWLY Install second seal in opposite side of rod end as shown En- sure the seals spring faces out when installing PRESS SEAL SLOWLY Fig B SEAL DIRECTION IS CRITICAL ENSURE SEAL SPRING FACES AWAY FROM ROD END [OUT] WHEN INSTALLING STEP 11 Fig C...
- Page 34 GENERAL SAFETY STEP 12 Install NEW high pressure static seal [A] in blind end [B] as shown STEP 15 Re-install plunger [A] into plunger receiver [B] as shown STEP 13 Install NEW low pressure static seal [A] in rod end [B] as shown STEP 14 STEP 16 Mate Rod end to blind end and secure with mount screws (x4)
- Page 35 STEP 19 Connect all previously installed suction and discharge lines to STEP 17 the fluid end Secure FMT fluid end assembly to existing drive by installing CAUTION! mount screws (x2) as shown Only properly qualified and trained personnel should be involved in the setting up, putting into service, inspecting and repairing of this equipment Ensure National, Provincial/State and local codes are followed...
- Page 36 GENERAL SAFETY Tie-In kit assemblies and in-line filter assemblies are available direct from MCI Kits include all tubing [where applicable] and fittings required to complete the instal- lation Contact customer service for more information: +1 888 263 4565 STEP 20...
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Page 37: Check Valve Maintenance
Check Valve Maintenance STEP 4 Remove check valve ball [A] and O-ring [B] from suction bush- Please ensure you have fully read and understood the ing, as shown general safety section of this manual before proceeding with any maintenance procedures USE CAUTION NOT TO SCRATCH SEAL FACES WHEN RE- MOVING SEALS STEP 1... - Page 38 GENERAL SAFETY STEP 6 STEP 8 Remove discharge check valve components shown Clean all Thread check valve assembly into fluid end body [Torque 90- items as required 100 In-lbs] INSPECT PORTING IN MAIN PUMP BODY FOR ANY DEBRIS AT THIS TIME. IF CLEANING IS REQUIRED PLEASE REFER TO ‘PLUNGER SEAL MAINTENANCE’...
- Page 39 STEP 10 Clean pump body as required then re-install discharge check valve components in order shown shown STEP 13 Connect all previously installed suction and discharge lines to the fluid end CAUTION! STEP 11 Only properly qualified and trained personnel should be involved in the setting up, putting into service, inspecting and repairing of this equipment Thread discharge check valve bushing [A] into fluid end body...
- Page 40 GENERAL SAFETY Tie-In kit assemblies and in-line filter assemblies are available direct from MCI Kits include all tubing [where applicable] and fittings required to complete the instal- lation Contact customer service for more information: +1 888 263 4565 STEP 14...
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Page 41: Limited Warranty
(i) to damage caused by accident, abuse or misuse, (ii) to damage caused by service performed by anyone who is not authorised to do so by MCI or (iii) to a product or part... -
Page 42: Maintenance Log
GENERAL SAFETY Maintenance Log DATE ACTIVITES PERFORMED PERFORMED BY www.mcisolutions.ca... - Page 43 Maintenance Log DATE ACTIVITES PERFORMED PERFORMED BY www.mcisolutions.ca...
- Page 44 DRIVEN BY OUR DRIVES WWW.MCISOLUTIONS.CA SS2 SITE 26 COMP 2 8540 OLD FORT RD. FORT ST JOHN, BC V1J 4M7 250.263.0977 TOLL FREE: +1.888.263.4565 FAX: +1.250.263.0978 Local Distributor: 1102-12-r01-MM...